3d build platform refill opening and cap

ABSTRACT

In example implementations, an apparatus includes a build platform and a cap. The build platform has an opening on a top surface to fill a build material storage unit. The cap is inserted into the opening to seal the opening. A top surface of the cap and the top surface of the build platform have a uniform thermal conductivity when the cap is inserted into the opening.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/084,141, filed on Sep. 11, 2018, which is a 371(c) National PhaseApplication of International Application No. PCT/2016/032133, filed May12, 2016, both of which are herein incorporated by reference in theirentireties.

BACKGROUND

Three dimensional (3D) printers, also referred to as additivemanufacturing machines, commonly operate by using a material to generatea 3D object layer-by-layer. In some 3D printing systems, powder isdelivered to a build platform from a powder storage unit. A layer of thepowder is leveled and excess powder can be recycled. Portions of thelayer of powder can be printed and fused using an energy source. The 3Dprinting system can operate at high temperatures to melt and fuse theportions of powder that are printed when building a part.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a side view of an example of a 3D printingsystem of the present disclosure;

FIG. 2 is a block diagram of an example build unit of the 3D printingsystem;

FIG. 3 is a cross-sectional diagram of an example build unit;

FIG. 4 is isometric view of an example of a cap;

FIG. 5 is a side view of an example handle on the cap;

FIG. 6 is an isometric view of an example of the cap in an opening in atop surface of a build platform;

FIG. 7 is a cross-sectional diagram of an example of the opening in thetop surface of the build platform;

FIG. 8 is a cross-sectional diagram of an example of a supply hoseconnected to the opening; and

FIG. 9 is a flow diagram of an example method for supplying buildmaterial through an opening in a top surface of a build platform.

DETAILED DESCRIPTION

The present disclosure discloses examples of a build platform on a buildunit that includes an opening in a top surface of the build platform anda cap. The build unit has an opening in a top surface of a buildplatform of the build unit. The opening may provide access to anenclosed build material storage unit within the build unit and below thebuild platform. As a result, the build material storage unit may berefilled with build material via a gravity fill as quickly as possible.Any clouds of dust are contained within the build material storage unitand do not form in the print zone over the build platform.

The opening in the top surface of the build platform provides easyaccess to the powder storage unit. For example, the opening allows anoperator to easily view a powder level remaining in the powder storageunit. In addition, the powder may be periodically changed or the powderstorage unit may be periodically cleaned. As a result, the openingallows for easy access to the powder storage unit.

In addition, when the opening is plugged with a cap, the top surface andthe cap may be designed to have uniform thermal conductivity to ensurethat the entire top surface has an even temperature profile. Forexample, integrity of the part being printed can be compromised if acool spot forms over the cap, or there are large temperature differencesbetween the cap and the top surface of the build platform.

FIG. 1 illustrates an example of a 3D printing system 100. The 3Dprinting system may include a build unit 102, a printer or 3D printer104 and a build material supply/post-processing component 106. In oneimplementation, the build unit 102 may store a build material that isused to build a part using additive printing/processing layer by layer.The build material may be a powder (e.g., a metallic powder, a ceramicpowder, and the like). In addition, the build unit 102 may provide avertically movable build platform upon which the part is built. Thebuild material may be delivered up from the sides of the build unit 102onto the build platform. The build platform may move lower after eachlayer is printed.

In one example, the build unit 102 may be connected to the buildmaterial supply/post-processing component 106 to receive the buildmaterial. For example, FIG. 1 shows the build materialsupply/post-processing component 106 with the build unit 102 connected.

After the build unit 102 receives the build material, the build unit 102may be disconnected from the build material supply/post-processingcomponent 106 and connected to the printer 104. FIG. 1 shows the printer104 with the build unit 102 connected.

In some implementations, the printer 104 may have a first print head forapplying a fusing agent to areas of the build material that will befused to print a layer of the part that is being printed. The firstprint head may also apply a detailing agent on some areas of the buildmaterial to help prevent the build material from fusing in the areasthat will not be fused. Then the printer 104 may have a second printhead that applies energy to fuse the areas of the build material withthe fusing agent. The build platform of the build unit 102 may belowered and a new layer of build material may be added on top of thelayer of build material that was printed. The process may be repeateduntil the part is completed.

The build unit 102 may be removed from the printer 104 after printing ofthe part has completed. The build unit 102 can then be connected to thebuild material supply/post-processing component 106 again to extract thepart. In addition, the build material supply/post-processing component106 may also recover and recycle the unfused build material.

Although the build unit 102 is shown as being a separate component fromthe printer 104, it should be noted that the build unit 102 may be partof the printer 104. For example, the build material may be supplied inthe printer 104 and the build platform may be part of the printer 104rather than being deployed as part of a removable build unit such as thebuild unit 102.

FIG. 2 illustrates an example block diagram of the build unit 102 thatincludes an opening 206 on a top surface 212 of a build platform 210. Inone example, feed trays 204 may be located on each side of the buildplatform 210.

In one implementation, the build platform 210 may be vertically movablewithin the build unit 102. For example, as build material is placed onthe build platform 210, printed and fused, the build platform 210 may belowered to receive another layer of build material. Then the process maybe repeated until the 3D part is completely printed.

In some implementations, the opening 206 may be easily accessible by auser or a technician. In other words, a user does not need to climb aladder or a contraption above the build unit 102 to access the opening206. In one example, the opening 206 may be located at a height of lessthan six feet high. For example, the opening 206 may be located at acounter height of approximately four feet to five feet high.

FIG. 3 illustrates a cross-sectional diagram of the build unit 102. Abuild material storage unit 208 may be located below the opening 206 andthe top surface 212 of the build platform. The build material storageunit 208 may be enclosed and store a build material used to print a partvia the additive process of the 3D printing system 100.

In one implementation, the build material may be fed up the sides of thebuild material storage unit 208 via an auger that dispenses the buildmaterial through the feed trays 204. The build material may be dispensedinto a print zone 302.

As discussed above, the build material storage unit 208 may be enclosedand located below the build platform 210. As a result, the buildmaterial storage unit 208 may be quickly filled with build material viaa gravity fill system. In addition, no hazardous dust clouds of buildmaterial may form in the print zone 302 from quickly pouring the buildmaterial into the build material storage unit 208.

In one embodiment, the opening 206 may also provide easy access to thebuild material storage unit 208. For example, an operator may quicklyview the build material level by looking into the opening 206. Inaddition, the opening 206 may provide easy access to change the buildmaterial or clean the inside of the build material storage unit 208.

In one example, the opening 206 may be a circular shape and located in acenter of the top surface 212 of the build platform 210. However, itshould be noted that the opening 206 may be any shape and locatedanywhere on the top surface 212 of the build platform 210.

FIG. 4 illustrates an isometric view of an example of a cap 400 that maybe inserted into the opening 206 to plug or seal the opening 206. In oneexample, the cap 400 may include a top portion 402, a body portion 404and a handle 406. The top portion 402 may be coupled to the body portion404 (or molded as a single integral piece) and may have a shape thatcorresponds to the opening 206. For example, if the opening 206 iscircular, the top portion 402 and the body portion 404 may also have acorresponding circular shape of similar dimensions (e.g., length, width,diameter, and the like) as the opening 206.

In one implementation, the top portion 402 and the body portion 404 maybe fabricated from a conductive material that has a conductivity similarto the top surface 212 of the build platform 210. In other words, thecap 400 may be a conductive cap. In one example, the top portion 402 andthe body portion 404 may be fabricated from a same metal as the topsurface 212 of the build platform 210. In other words, if the topsurface 212 of the build platform 210 is made from aluminum, a metalalloy, and the like, then the top portion 402 and the body portion 404may be fabricated from the same aluminum, metal alloy, and the like. Asa result, the entire top surface 212, including a top surface of the topportion 402 of cap 400, may have the same thermal conductivity and nodifferences in temperature gradients may be formed on the top surface212 of the build platform 210. In other words, the top portion 402 ofthe cap 400 and the top surface 212 of the build platform 210 may have auniform thermal conductivity.

In one implementation, the body portion 404 may include a matingmechanism 410 to mate with a corresponding mechanism in the opening 206.For example, the mating mechanism 410 may be a mechanical connectionsuch as a twist and lock mechanism, or threads to allow the cap 400 tobe screwed in, a lock with springs and ball plungers, magnets, and thelike.

In some implementations, the mating mechanism 410 may be oriented suchthat the handle 406 is positioned to fall in a direction of movement ofa spreader of the printer 104 when the cap 400 is inserted into theopening 206. In other words, the mating mechanism 410 may ensure thatthe handle 406 is in a position such that as a build material spreadermoves over the build platform 210, the spreader may knock down thehandle 406 without interfering with the movement of the spreader.

In one example, the handle 406 may be coupled to the top portion 402.The top portion 402 may also include a cavity 408. The cavity 408 mayhave a similar shape (e.g., the shape of the outer perimeter andthickness) as the handle 406. The handle 406 may rest in the cavity 408such that the top surface 212, the top portion 402 and the handle 406are all co-planar during operation of the printer 104. In other words,the top surface 212, the top portion 402 and the handle 406 lie on asingle plane or the same plane. Said another way, the top surface of thehandle 406 when resting in the cavity 408 is not lower than the topsurface of the top portion 402 of the cap 400. As a result, the topportion 402 and the handle 406 may not interfere with operation of therollers and printer carriage of the printer 104. In addition, the topportion 402 and the handle 406 may not cause changes in elevation in thelayers of build material that are spread across the top of the buildplatform.

FIG. 5 illustrates a side view of an example of the handle 406. In oneimplementation, the handle 406 may be designed to have a range of motionof less than 90 degrees relative to the top surface 212 of the buildplatform to 0 degrees when resting in the cavity 408.

For example, FIG. 5 illustrates an angle 502 measured between a dashedline 504 and the top surface 212. The dashed line 504 is illustrated asbeing at an angle of 90 degrees relative to the top surface 212. Thehandle 406 may be designed to have a range of motion that does not reachthe dashed line 504 to a resting position flush in the cavity 408.

The design of the range of motion of the handle 406 ensures that thehandle 406 will fall via gravity. The range of motion of the handle 406,the design of the mating mechanism 410 that ensures that the handle 406falls in a direction of movement of the spreader into the cavity 408,and the cap 400 may be designed to ensure no component interferes withthe movement of the spreader or other mechanical portions of the printer102 during processing of the build material.

For example, FIG. 6 illustrates an example of the cap 400 that isinserted into the opening 206 in the top surface 212 of the buildplatform 210. The handle 406 may reset in the cavity 408 such that thetop portion 402 of the cap 400 is flush, co-planar, or on the sameplane, with the top surface 212 of the build platform 210. In otherwords, when build material is laid on top of the build platform 210 andflattened by the spreader, no changes of elevation would exist in thebuild material.

FIG. 7 illustrates a cross-sectional diagram of an example of theopening 206 in the top surface 212 of the build platform 210. In oneembodiment, the opening 206 may include a corresponding mating mechanism708. For example, the mating mechanism 410 of the cap 400 may align andmate with the corresponding mating mechanism 708 of the opening 206. Asdescribed above, in some implementations, the corresponding matingmechanism 708 may be aligned such that when the cap 400 is inserted intothe opening, the handle 406 will fall in a direction of movement of thespreader.

In one example, the opening may include a bottom ring 706. The surfaceof the bottom ring 706 may include a hose valve opening mechanism 702and a magnet 704. FIG. 8 illustrates an example of a supply hose 802that is inserted into the opening 206 to fill the build material storageunit 208 with build material. The hose 802 may include a valve 804 toprevent loose build material from spilling out of the hose 802. The hose802 may also include a sensor 806 to detect the magnet 704.

In one example, the sensor 806 may detect the magnet 704 indicating thatthe hose 802 has been inserted into the opening 206 properly. In oneexample, the hose valve opening mechanism 702 may comprise a hook thatprotrudes perpendicular to a surface of the bottom ring 706. The hookmay turn and lock the valve 804 into an open position. As a result, whenthe hose 802 is properly inserted into the opening 206 (e.g., asindicated by the sensor 806 detecting the magnet 704) the valve 804 maybe opened and ready for filling the build material storage unit 208.

FIG. 9 illustrates a flow diagram of an example method 900 for supplyingbuild material through an opening in a top surface of a build platform.In one example, the blocks of the method 900 may be performed the buildunit 102 or the 3D print system 100.

At block 902, the method 900 begins. At block 904, the method 900provides for a conductive cap to be removed from an opening in a topsurface of a 3D build platform. For example, the conductive cap may beremoved to allow for access to the opening. The 3D build platform may belocated on top of a movable build unit. The build unit may be moved intoa build material supply/post-processing component of a 3D printingsystem after the conductive cap is removed.

In one example, the conductive cap may be removed with a handle that iscoupled to a top surface of the conductive cap. The handle may rest in acavity in the top surface of the conductive cap and be designed toautomatically fall into the cavity even if the handle is accidently leftup.

At block 906, the method 900 provides for a supply hose to be insertedinto the opening. In one example, the supply hose may be part of thebuild material supply/post-processing component of a 3D printing system.The supply hose may be used to fill the build material storage unit inthe build unit with build material that is used to print a 3D part.

At block 908, a presence sensor is triggered to determine that thesupply hose is connected. In one example, the build unit may not containany sensors due to the high operating temperatures used in 3D printing.Rather, the sensors may be contained in the supply hose. The opening inthe build unit may contain a magnet that is detected by the presencesensor on the supply hose to indicate that the supply hose has beenproperly inserted into the opening.

In addition, the opening may contain a hose valve opening mechanism thatopens a valve at an end of the supply hose. For example, an end of thesupply hose may have a valve to prevent loose or excess build materialfrom spilling out of the supply hose. The hose valve opening mechanismmay cause the mechanical valve on the end of the supply hose to open andremain open.

At block 910, build material is supplied into an enclosed build materialstorage unit below the 3D build platform. In one example, the buildmaterial may be supplied via a gravity fill. In other words, the buildmaterial may be poured from a source that is located above the openingin the build unit.

In addition, the build material may be poured at a maximum speed orwithout any pouring speed control. Since the build material storage unitis enclosed below the top surface of the build platform, any clouds ofbuild material will remain inside the build material storage unit. Thebuild material may be supplied into the build material storage unit asquickly as possible without fear of forming potentially dangerous cloudsof build material.

At block 912, the conductive cap is replaced into the opening in the topsurface of the 3D build platform. For example, the supply hose may bedisconnected and the build unit may be removed from the build materialsupply/post-processing component. The conductive cap may be placed intothe opening and the build unit may be moved to the printer to build the3D part. For example, the handle may be used to align a mating mechanismon the conductive cap with a corresponding mating mechanism in theopening. After the conductive cap is inserted, the handle may be loweredinto the cavity in the top surface of the conductive cap. When thehandle is lowered, the handle, the top surface of the conductive cap andthe top surface of the build platform of the build unit may beco-planar. At block 914, the method 900 ends.

It will be appreciated that variants of the above-disclosed and otherfeatures and functions, or alternatives thereof, may be combined intomany other different systems or applications. Various presentlyunforeseen or unanticipated alternatives, modifications, variations, orimprovements therein may be subsequently made by those skilled in theart which are also intended to be encompassed by the following claims.

1. An apparatus, comprising: a build platform having a build materialstorage unit; an opening formed on a top surface of the build platformand over the build material storage unit, wherein the opening is toreceive a hose to fill the build material storage unit; and a cap toseal the opening, when the cap is inserted into the opening.
 2. Theapparatus of claim 1, wherein the cap comprises: a top portion; a bodyportion coupled to the top portion, wherein the body portion comprises amating mechanism to mate with the opening in the top surface of thebuild platform; and a handle coupled to the top portion, wherein thehandle rests in a cavity in the top portion.
 3. The apparatus of claim2, wherein the top portion and the handle are co-planar with the topsurface of the build platform when the handle rests in the cavity in thetop portion.
 4. The apparatus of claim 2, wherein the mating mechanismcomprises at least one of: a twist and lock mechanism or threads.
 5. Theapparatus of claim 2, wherein the handle has a range of motion from lessthan 90 degrees relative to the top surface of the build platform to 0degrees resting in the cavity.
 6. The apparatus of claim 1, wherein thebuild platform is vertically movable within the apparatus.
 7. Theapparatus of claim 1, wherein the opening comprises a mechanism to opena valve on the hose.
 8. The apparatus of claim 1, wherein the openingcomprises a magnet that provides feedback indicating that the supplyhose is connected.
 9. An apparatus, comprising: a build platform for a3D printer; an enclosed build material storage below the build platform;and an opening in a top surface of the build platform that providesaccess to the enclosed build material storage, wherein the openingcomprises: a hose valve opening mechanism coupled to a bottom ring foropening a valve on a supply hose that rests against the bottom ring. 10.The apparatus of claim 9, wherein the opening comprises a matingmechanism to mate with a cap.
 11. The apparatus of claim 10, wherein themating mechanism aligns the cap such that a handle on the cap falls downin a direction that a spreader moves.
 12. The apparatus of claim 10,wherein a top surface of the cap and a top surface of the build platformhave a uniform thermal conductivity.
 13. The apparatus of claim 10,wherein the cap fills the opening.
 14. The apparatus of claim 9, whereinthe hose valve opening mechanism comprises a hook that protrudesperpendicular to a surface of the bottom ring.
 15. The apparatus ofclaim 9, wherein the supply hose includes a sensor to indicate that thesupply hose is correctly connected into the opening.
 16. A method,comprising: removing a cap from an opening in a top surface of a threedimensional (3D) build platform; supplying build material into anenclosed build material storage below the 3D platform at a maximum ratewithout a pouring speed control via a supply hose inserted into theopening; and replacing the cap into the opening in the top surface ofthe 3D build platform after the supplying the build material iscompleted and the supply hose is removed from the opening.
 17. Themethod of claim 16, wherein a presence sensor is triggered in responseto the supply hose being correctly inserted into the opening.
 18. Themethod of claim 17, wherein the presence sensor is triggered by a magnetin the opening.
 19. The method of claim 16, wherein the cap is removedvia a handle that rests in a cavity in a top surface of the cap.
 20. Themethod of claim 16, wherein the cap is replaced by aligning a matingmechanism on the cap with a corresponding mating mechanism in theopening.